Method for producing fibers



Feb. 25, 1969 T. E. CROMPTON 3,429,953

METHOD FOR PRODUCING FIBERS Filed June 16, 1955 R O T N E V W.

THOMAS E. CROMPTON QM /M ATTORNEY United States Patent 3,429,953 METHOD FOR PRODUCING FIBERS Thomas E. Crompton, Cary, N.C., assignor to Monsanto Company, St. Louis, Mo., a corporation of Delaware Filed June 16, 1965, Ser. No. 464,477 US. Cl. 264-8 Claims Int. Cl. B22d 1 3/ 00, 23/08 ABSTRACT OF THE DISCLOSURE Fine fibers having diameters in the range of about 5 microns to about 0.1 micron are produced by feeding a This invention relates to the production of fibers. More particularly, this invention relates to a method for the production of fine fibers of a synthetic organic polymer.

Heretofore, fine fibers of synthetic organic polymers have been made by processes which involve the action of a high velocity jet of gas on a molten polymeric material. In accordance with these known processes, a molten polymer is extruded through one or more orifices into a gas stream of high velocity. The gas stream acts to break up the molten stream into small particles, which solidify, and are carried away by the gas stream. While these processes have been successful to some extent, a major problem encountered is the lack of uniformity in the shape and size of the fibers produced. When the gas stream acts on .the molten polymer stream the particle forms vary greatly in size. Furthermore, when these particles are solidified, globules or beads are formed along with the fibers due in part to the difference in size and also due to the fact that some solidification occurs as the gas stream contacts the molten polymer.

Additionally, these previously known processes have been somewhat restricted in their application in the use of a molten polymer feed. In these previously known processes, the use of a polymer solution as a feed is extremely diflicult due to the low viscosity of the solution and also due to the difficulties encountered in solvent re moval.

It is therefore an object of this invention to provide a method for the production of uniform fine fibers of a synthetic organic polymer.

It is a further object of this invention to provide a method for the production of uniform fine fibers of a synthetic organic polymer from a solution of said polymer.

Other objects will become apparent from the following description.

Briefly, the method of the present invention involves feeding a solution of a synthetic organic polymer onto the internal, concave face of a rotating conoid surface, allowing said solution to substantially cover said internal concave face and be discharged as elongated droplets from the periphery of said surface by the centrifugal force resulting from the rotation of said surface, surrounding the periphery of said surface with an annular gas stream flowing substantially parallel with the axis of rotation of said surface, entraining the discharged droplets in said gas stream, removing solvent from said droplets by the action of said gas stream thus forming fine fibers of said polymers in said gas stream, and recovering said fibers formed in said stream.

3,429,953 Patented Feb. 25, 1969 The process will be more fully understood with reference to the accompanying drawings in which:

FIGURE 1 is a perspective view of the fiber-forming apparatus of this invention;

FIGURE 2 is a sectional top view of the apparatus shown in FIGURE 1 at line 22;

FIGURE 3 is a perspective view of a form of apparatus used to collect the fibers formed by the present invention, and

FIGURE 4 is a view of a preferred form of the conoid disc used in the present invention.

There is shown in FIGURE 1 a typical arrangement of the apparatus used to carry out the present invention. A solution of a synthetic organic polymer from source 1 is passed via line 2 and pump 3 through tubular feeding means 4 onto the internal concave face of conoid disc 5 through the aperture 6. The pump 3 provides constant pressure to the solution thus allowing the solution to essentially cover the concave face of disc 5. The disc 5 is rotatably mounted in casing 7 and is rotated by chain drive 8 and motor 9. In order to produce the uniform fine fibers by the method of the present invention, the conoid disc should be capable of rotating at speeds between 1000 r.p.m. and 7000 r.p.m., preferably between 2000 and 4000 r.p.m. A gas, for example, air, from a source not shown, is forced "by pump 10 through heating means 11 and line 12 and out vaned annular opening 13 into enclosure 14. The poly-mer solution is discharged from disc 5, by the centrifugal force resulting from its rotation, in the form of elongated droplets which are picked up in the gas stream exiting from opening 13, are carried through enclosure 14 and deposited on gathering means 15, which is shown in the form of a screen. During the passage of the droplets from disc 5 to screen 15, the action of the gas stream removes the solvent from the polymer solution thus forming fine fibers which are deposited on screen 15. Screen 15 is preferably in the form of an endless belt which is moved by drive means 17 and motor 18 in a direction perpendicular to the axis of rotation of disc 5. As the screen moves out of enclosure 14 the fibrous mat 16 formed thereon is removed and taken up, for example, on take up roll 19 driven by motor 20. The solvent remaining in the gas stream passes through the screen and is directed by baflies 22 and 23 shown in FIGURE 2 to solvent collection means 21.

While FIGURE 1 shows the removal of the fibers from the gathering means in the form of a mat, it is also possible, and in somecases desirable, to remove the fibers in the form of a yarn. This may be done by the apparatus shown in FIGURE 3 wherein air jets 24 serve to decrease the width of mat 17 as it passes over roll 19. The fibers are further compacted by passage through guide 25, over roll 26 and through guide 25(a). The yarn 27 is thence taken up on bobbin 28.

Rotating disc element 5 is more clearly shown in FIG- URE 4. This element as shown in FIGURE 4 is composed of tubular neck portion 5(a) and conoid discharge surface 5(b) flaring outwardly therefrom. As shown in FIGURE 4, aperture 6 must be located centrally in disc 5. This allows uniform distribution of the polymer solution over the entire face of the disc. It is also desirable that the disc 5 terminate in a sharp edge periphery 29. This allows the solution to leave the face of the disc in elongated droplets which pass into the surrounding gas stream and also serves to prevent the solution from back flowing over the convex side of disc 5. In accordance with a preferred method of the present invention, the polymer solution is allowed to cover the inside surface of tubular neck portion 5(a) prior to its passage through aperture 6 onto discharge surface 5(b). This insures a more even distribution of the solution onto the discharge surface.

Any synthetic organic polymer that is solution-spinnable may be used in the process of the present invention. Thus,

in accordance with the present invention, fibers may be made from poly-acrylonitrile, polycarbonates, polyurethanes, and other like polymers which may be dissolved in a solvent and fed to the rotating disc. Likewise, mixtures of fibers may be spun in accordance with the process of the present invention either by admixing the solutions prior to their introduction through the feeding means, by having a plurality of feeding means through the aperture of the conoid disc, or by providing a plurality of discs on the same shaft. The preferred polymer for use in the method of the present invention comprises acrylonitrile and copolymers thereof.

Due to obvious economic advantages, it is preferred in accordance with the process of the present invention to employ air as the annular gas stream surrounding the periphery of the rotating disc. Since it is highly desirable that most of the solvent be removed from the polymer prior to its reaching the target, it is preferred to heat the incoming air stream in order to achieve this end. It has been found that an air stream heated to a temperature of between about 100 C. and about 350 0, preferably 250 C. to 300 C., serves to insure solvent removal from the fibers.

It is necessary that the annular gas stream be traveling at a velocity sufficient to overcome the centrifugal force imparted to the elongated droplets by the rotatingcone and entrain the droplets of solution to the gathering means. Furthermore, the velocity must be sufiicient to remove the solvent from the droplets. A gas stream velocity of between 1500 feet per minute and 6000 feet per minute has been found necessary for this purpose with the preferred gas velocity lying between the ranges of 2000 feet per minute and 4000 feet per minute.

The shape of disc *5 is preferably that of a cone although other shapes, for example, saucer-like shapes may be equally well employed. The only requirement is that disc 5 be of a shape which allows uniform distribution of the polymer solution over the entire face thereof.

It has been found that the concentricity of the disc is an important factor in the successful operation of the process and apparatus of this invention. That is, the peripheral edge of disc 5 must be substantially completely concentric with its axis of rotation and with the periphery of aperture 6. When disc 5 is out-of-round to any substantial degree, the polymer solution does not discharge evenly over its entire peripheral surface and globule formation results.

Fibers made in accordance with the process of the present invention are essentially uniform in shape and size. Bead formation is essentially eliminated and the diameters of the fibers range from about 5 microns to about 0.1 micron with the average diameter being between 1 and 2 microns. The fibers produced by the present invention have outstanding properties which make them useful for paper products, laminates, absorbent pads, filters, insulation and the like.

I claim:

1. A method for producing fine fibers from a synthetic organic polymer which comprises feeding a solution of said polymer onto the internal concave face of a rotating conoid surface, allowing said solution to substantially cover said internal concave face and be discharged as elongated droplets from the periphery of said surface by the centrifugal force resulting from. the rotation of said surface, surrounding the periphery of said surface with an annular gas stream flowing substantially parallel with the axis of rotation of said surface, entraining the discharged droplets in said gas stream, removing solvent from said droplets by the action of said gas stream thus forming fine fibers of said polymer in said gas stream, and recovering said fibers from said stream.

2. The method as described in claim 1 wherein the synthetic organic polymer comprises a member selected from the group consisting of acrylonitrile and copolymers thereof.

'3. The method as described in claim 1 wherein the solution is fed to the rotating surface under pressure.

4. The method as described in claim 1 wherein the annular gas stream is heated to a temperature of between about 100 C. and about 350 C. and has a velocity between 1500 and 6000 feet per minute.

5. The method as described in claim 1 wherein said solvent remains in said flowing gas stream and is collected at a point downstream of the point where the fibers are removed.

References Cited UNITED STATES PATENTS 2,187,877 l/1940 Ferris et al 260-87.1 3,097,085 7/1963 Wallsten l82.5 2,793,395 5/1957 Richardson 182.5

ROBERT F. WHITE, Primary Examiner.

J. R. HALL, Assistant Examiner.

U.S. Cl. X.R. 182.5 

